2 Stroke 40 Horsepower

2005
2 Stroke
40 HORSEPOWER
R, RL
! WARNING !
Read this Operator Guide thoroughly. It contains important

safety information. When operating your boat, always
have this Operator Guide onboard.
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Our First Words to the Owner/Operator
This Operator’s Guide is an essential part of your Johnson outboard. It contains pertinent information
which, if followed, will provide you with a thorough understanding needed for proper operation, mainte-
nance, care and above all safety!
The safety section of this Guide comes first because it is our first priority and it should be yours too. It is
strongly recommended that you read this Guide from front cover to rear cover. Following this recommen-
dation will assure the completeness of the information that is essential to your safety, the safety of any
passengers and other boaters. An Operator’s Readiness Test has been prepared on the last page of this
Guide.
Be safe! All passengers should be familiar with the proper operation of your boat and Johnson outboard.
Be certain they fully understand and respect the controls and operation. Each operator is responsible for
the safety of all passengers and other boaters. Please make safety your first priority and complete a boat-
ing safety course through your local Coast Guard, Power Squadron, Red Cross or State Boating Law
Agency.
The pleasures of owning and operating a Johnson outboard can be significant. We strongly believe the
rewards for following our recommendations will be worthwhile. Remember that YOU are the key to safety.
Good safety practices not only protect you but also protect the people around you.
Having fun is what it’s all about and, with your cooperation, the pertinent information in this Guide can en-
sure a safe and enjoyable experience.
Enjoy the great outdoors on the water...
WARNING
Be careful! Human error is caused by many factors: carelessness, fatigue, overload, preoccu-
pation, unfamiliarity of operator with the product, drugs and alcohol to name a few. Damage to
your boat and outboard can be fixed in a short period of time, but injury or death has a lasting
effect.
For your safety and the safety of others, read this Guide from cover to cover and follow all
safety warnings and recommendations. Do not disregard any of the safety precautions and
instructions.
Anyone operating your boat should first read and understand this Guide before they operate
your boat and motor.
The following trademarks are the property of Bombardier Motor Corporation of America or its affiliates:
2+4® fuel conditioner Johnson®

Evinrude® S.L.O.W.™
Evinrude®/Johnson® anti-corrosion spray Triple-Guard® grease
Evinrude®/Johnson® Genuine Parts Touch-Trim™
Evinrude®/Johnson® XD25™ Formula Twist-Grip™
Hi-Vis™ gearcase lubricant Ultra-HPF™ gearcase lubricant

Contents
GENERAL INFORMATION ................................................................................................... 2
SAFETY — THE RIGHT PLACE TO GET STARTED ................................................................................................ 2
PRODUCT REFERENCES, ILLUSTRATIONS AND SPECIFICATIONS ................................................................... 4
BOMBARDIER MOTOR CORPORATION OF AMERICA LIMITED WARRANTY FOR 2005 JOHNSON
2-STROKE OUTBOARD ENGINES SOLD IN THE UNITED STATES AND CANADA ..................................... 5
BOMBARDIER MOTOR CORPORATION OF AMERICA LIMITED WARRANTY FOR 2005 JOHNSON
2-STROKE OUTBOARD ENGINES SOLD OUTSIDE THE UNITED STATES AND CANADA ......................... 8
FEATURES ............................................................................................................................................................... 10
ENGINE SPECIFICATIONS ...................................................................................................................................... 12
EMERGENCY STOP SWITCH .................................................................................................................................. 13
FUEL AND OIL ................................................................................................................... 14
FUEL ......................................................................................................................................................................... 14
OIL ............................................................................................................................................................................. 14
ADDITIVES ................................................................................................................................................................ 15
FUEL/OIL RATIO ...................................................................................................................................................... 15
MIXING FUEL AND OIL ............................................................................................................................................ 15
FUEL SYSTEMS ....................................................................................................................................................... 16
BREAK-IN (10 HOURS) ............................................................................................................................................ 16
ENGINE STARTING ........................................................................................................... 17
BEFORE START-UP ................................................................................................................................................. 17
ENGINE STOPPING ................................................................................................................................................. 19
SHIFTING AND SPEED CONTROL ......................................................................................................................... 20
EMERGENCY STARTING ........................................................................................................................................ 20
FUEL ECONOMY ...................................................................................................................................................... 21
OPERATION ....................................................................................................................... 22
MANUAL TRIM ......................................................................................................................................................... 22
TRAILERING ............................................................................................................................................................. 24
TILTING ..................................................................................................................................................................... 24
TILT SUPPORT ......................................................................................................................................................... 25
MOTOR ANGLE ADJUSTMENT .............................................................................................................................. 25
PROPELLER SELECTION ....................................................................................................................................... 26
MOORING ................................................................................................................................................................. 26
FLUSHING ................................................................................................................................................................ 26
ENGINE OVERHEATING .......................................................................................................................................... 27
IMPACT DAMAGE .................................................................................................................................................... 28
STORING .................................................................................................................................................................. 28
SPECIAL OPERATING CONDITIONS ..................................................................................................................... 29
MAINTENANCE .................................................................................................................. 30
10-HOUR INSPECTION ............................................................................................................................................ 30
OFF-SEASON STORAGE ........................................................................................................................................ 30
PRE-SEASON SERVICE .......................................................................................................................................... 31
ADJUSTMENTS ........................................................................................................................................................ 32
LUBRICATION .......................................................................................................................................................... 33
WATER PRESSURE ................................................................................................................................................. 35
FUEL PUMP FILTER ................................................................................................................................................ 35
SPARK PLUGS ......................................................................................................................................................... 36
PROPELLER ............................................................................................................................................................. 36
ANTICORROSION ANODES .................................................................................................................................... 37
TROUBLE CHECK CHART ...................................................................................................................................... 38
ENGINE MAINTENANCE AND INSPECTION SCHEDULE ..................................................................................... 39
INSTALLATION ........................................................................................................................................................ 41
AC LIGHTING ........................................................................................................................................................... 44
© 2004 Bombardier Motor Corporation of America. All rights reserved.

TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.
1
GENERAL INFORMATION
SAFETY — THE RIGHT PLACE TO GET A responsible, educated boater will fully appreciate
the pleasures of boating and will be a safe boater.
STARTED Boating Safety Classes are conducted by the U.S.
Coast Guard Auxiliary, the U.S. Power Squadron
This Operator’s Guide contains essential informa- and some Red Cross Chapters. For information
tion to help prevent personal injury and damage to about classes, call toll free 1-800-336-BOAT. For
equipment. It will acquaint the operator and pas- additional information about boating safety and reg-
sengers with the Evinrude/Johnson outboard and ulations call: U.S. Coast Guard Boating Safety Hot-
its controls, operation, maintenance and boating line 1-800-368-5647. Outside North America
safety measures. Make sure all operators read, un- please contact your Dealer or distributor for details
derstand and follow the contents. This Guide about boating safety.
should be kept in a waterproof bag with the product
at all times during operation. If the product owner-
ship is transferred, this Guide should be forwarded SAFETY MEASURES — General
to the subsequent owners. To fully appreciate the pleasures, enjoyment
This Operator’s Guide uses the following signal and excitement of boating there are some ba-
words identifying important safety messages. sic rules that should be observed and followed
These safety alert signal words mean: by any boater. Some rules may be new to you
ATTENTION! and others may be common sense or obvi-
BECOME ALERT! ous... irrespective, take them seriously! Fail-
YOUR SAFETY IS INVOLVED! ure to follow this safety information and safe
boating rules could result in injury to you, your
passengers or other water users.
DANGER
Become completely familiar with the control
Indicates an imminently hazardous situa- and operation of your boat and motor before
tion which, if not avoided, WILL result in embarking on your first trip or taking on a pas-
death or serious injury. senger(s). If you have not had the opportunity
to do so with your Dealer, practice driving in a
suitable area and feel the response of each
control. Be familiar with all controls before ap-
plying the throttle above idle speed. As the op-
WARNING erator, you are in control and responsible for
safe operation.
Indicates a potentially hazardous situation
which, if not avoided, CAN result in severe SAFETY MEASURES — Operation
injury or death.
Be sure at least one of your passengers
knows how to handle your boat in case of an
emergency.
CAUTION All passengers should know the location of
emergency equipment and how to use it.
Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor or All safety equipment and personal flotation
moderate personal injury or property dam- devices must be in good condition and suit-
age. It also may be used to alert against able for your type of boat. Always comply with
unsafe practices. the regulations that apply to your boat.
Contact with rotating propeller is likely to result

IMPORTANT: Identifies information that will help in serious injury or death. Do not allow anyone
prevent damage to machinery and appears next to near a propeller, even when the engine is off.
information that controls correct assembly and op- Propeller blades can be sharp and can contin-
eration of the product. ue to turn even after the engine is shut off. Al-
Although the mere reading of such information ways shut off the engine when boat is near
people in the water.
does not eliminate the hazard, the understanding
and application of the information will promote the
correct use of your outboard engine.
2 - General Information
Whenever running the engine, assure there is Do not operate your boat if you are under the
proper ventilation to avoid the accumulation of influence of drugs or alcohol.
carbon monoxide (CO), which is odorless, col-
orless, and tasteless, and can lead to uncon- High performance boats have a high power-
sciousness, brain damage, or death if inhaled to-weight ratio. If you are not experienced in
in sufficient concentrations. CO accumulation the operation of a high performance boat, do
can occur while docked, anchored, or under- not attempt to operate one at, or near, its top
way, and in many confined areas such as the speed until you have gained that experience.
boat cabin, cockpit, swim platform, and heads.
It can be worsened or caused by weather, For more information, see your Evinrude/
mooring and operating conditions, and other Johnson Dealer for a copy of Introduction to
boats. Avoid exhaust fumes from your engine High Performance Boating, P/N 335763.
or other boats, provide proper ventilation, shut
off your engine when not needed, and be
aware of the risk of backdrafting and condi- SAFETY MEASURES — Installation and
tions that create CO accumulation. In high Maintenance
concentrations, CO can be fatal within min-
utes. Lower concentrations are just as lethal Outboard Installation
over long periods of time.
The outboard must be correctly installed. Fail-
Proceed with caution and at very low speed in ure to correctly install the outboard could re-
shallow water. Grounding or abrupt stops may sult in serious injury, death or property
result in personal injury or property damage. damage. We strongly recommend that your
Also be alert for debris and objects in the wa- Dealer install your outboard to ensure proper
ter. installation.
Be familiar with the waters you are operating Do not overpower your boat by using an en-
in. The gearcase of this outboard extends be- gine that exceeds the horsepower indicated
low the water surface and could potentially on the boat’s capacity plate. Overpowering
come in contact with underwater obstructions. could result in loss of control. If your boat has
Contact with underwater obstructions may re- no capacity plate, contact your Dealer or the
sult in loss of control and personal injury. boat’s manufacturer.
Avoid standing up or shifting weight suddenly Maintenance

in light weight boats. When replacement parts are required, use
Evinrude®/Johnson® Genuine Parts or parts
Keep your passengers seated in seats. The with equivalent characteristics, including type,
boat’s bow, gunwale, transom and seat backs strength and material. Using substandard
are not intended for use as seats. parts could result in injury or product malfunc-
tion.
Insist on the use of personal flotation devices,
approved by the U.S. Coast Guard, by all pas- Only perform service procedures which are
sengers when boating conditions are hazard- detailed in this Operator’s Guide. Attempting
ous, and by children and nonswimmers at all to perform maintenance or repair on your out-
times. board if you are not familiar with the correct
service and safety procedure could cause per-
Respect no wake zones, rights of other water sonal injury or death. Further information can
users and the environment. As the "skipper" be obtained from your authorized Evinrude/
and owner of a boat you are responsible for Johnson Dealer. In many instances proper
damage to other boats caused by the wake of tools and training are required for certain ser-
your boat. Allow no one to throw refuse over- vice or repair procedures.
board.
Maintain your boat and engine in top condition
Know the marine traffic laws and obey them. at all times. Adhere to the Engine Mainte-
nance and Inspection Schedule.
Remember, gasoline fumes are flammable Operate your boat and outboard prudently
and explosive. Always adhere to the fueling and have fun. Do not forget that all persons
procedure contained in this Operator’s Guide must assist other boaters in case of emergen-
and those given to you by the fueling station. cy.
Always verify fuel level before use and during
the ride. Apply the principle of 1/3 fuel to des-
tination, 1/3 back and 1/3 reserve fuel supply. Prevent injury from contact with rotating pro-
Do not carry spare fuel or flammable liquids in peller; remove propeller before flushing or be-
any storage or engine compartments. fore performing any maintenance.
General Information - 3
PRODUCT REFERENCES, Model and Serial Numbers
ILLUSTRATIONS AND The model and serial numbers appear on a plate at-
SPECIFICATIONS tached to the stern bracket or swivel bracket.
Record your outboard’s:
Model Number ___________________________

WARNING
Serial Number ___________________________
When replacement parts are required, use
Evinrude/Johnson Genuine Parts or parts Purchase Date ___________________________
with equivalent characteristics, including
type, strength and material. Using substan-
dard parts could result in injury or product Ignition Key Number ______________________
malfunction.
Stolen Outboards
Bombardier Motor Corporation of America (BMCA) North America — Report your outboard as stolen
reserves the right to make changes at any time, to Customer and Dealer Support Services, 250 Sea
without notice, to features, specifications and mod- Horse Drive, Waukegan, IL 60085 U.S.A. Give the
el availability. The right is also reserved to change outboard’s model and serial numbers and enclose
any specification or part at any time without incur- a copy of the police report.
ring any obligation to update older models. The in-
formation in the Guide is based on the latest Outside North America — Report the theft to the
specifications available at the time of publication. Bombardier Recreational Products distributor
where the outboard was registered.
Photographs and illustrations used in this Guide
might not depict actual models or equipment but
are intended as representative views for reference Technical Literature
only. The continuing accuracy of this Guide cannot BMCA offers technical literature specifically for your
be guaranteed. outboard. A service manual, a parts catalog, or an
Certain features of systems discussed in this Guide extra Operator’s Guide can be purchased from your
might not be found on all models in all marketing ar- selling Dealer. For the name and location of the
eas. nearest Evinrude/Johnson Dealer in the United
States and Canada log on to www.evinrude.com
or www.johnson.com.
Owner’s Identification
North America — At the time of purchase, your Declaration of Conformity

Dealer will complete your outboard registration BMCA declares that the outboard to which this Op-
forms. Your portion provides proof of ownership erator’s Manual applies conforms to the essential
and date of purchase. requirements outlined in CE Machinery Directive
Outside North America — See your Dealer or 98-37-EC, as amended.
distributor for details.
BOMBARDIER MOTOR CORPORATION OF AMERICA
LIMITED WARRANTY FOR 2005 JOHNSON 2-STROKE OUTBOARD ENGINES
SOLD IN THE UNITED STATES AND CANADA
1. SCOPE OF THE LIMITED WARRANTY

Bombardier Motor Corporation of America* ("BMCA") warrants its 2005 Johnson® 2-stroke outboard en-
gines sold by authorized Johnson dealers in the fifty United States and Canada ("Product") from defects
in material or workmanship for the period and under the conditions described below.
2. WARRANTY COVERAGE PERIOD

This limited warranty will be in effect from the date of purchase by the first retail consumer or the date the
Product is first put to use, whichever occurs first, for a period of:
TWENTY-FOUR (24) CONSECUTIVE MONTHS for private, recreational use; or
TWELVE (12) CONSECUTIVE MONTHS for commercial use. The Product is used commercially when it
is used in connection with any work or employment that generates income, during any part of the warranty
period. The Product is also used commercially when, at any point during the warranty period, it is installed
on a boat that has commercial tags or is licensed for commercial use.
The repair or replacement of parts or the performance of service to Product under this warranty does not
extend the life of this limited warranty beyond its original expiration date. All Evinrude®/Johnson Genuine
Parts and accessories installed by an authorized dealer at the time of sale, including but not limited to pro-
pellers, bear the standard BMCA parts and accessories one-year limited warranty.
3. CONDITIONS TO HAVE WARRANTY COVERAGE

This warranty coverage is available only on Johnson 2-stroke outboard engines purchased as new and
unused from a dealer authorized to distribute Johnson products in the country in which the sale occurred
("Dealer"), and then only after the BMCA specified pre-delivery inspection process has been completed
and documented by the purchaser and Dealer. Warranty coverage only becomes available upon proper
registration of Product by Dealer or owner.
Only the original purchaser and any subsequent owners who reside in the United States and Canada and
have purchased Product from a U.S. or Canadian Dealer are eligible for warranty registration and warran-
ty coverage hereunder. Such limitations are necessary in order to allow BMCA to protect the safety of its
products, its consumers, and the general public.
As outlined in the Operator's Guide, timely routine required maintenance must be performed to maintain
warranty coverage. BMCA may require proof of proper maintenance prior to authorizing warranty cover-
age.
4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE

The registered owner must notify an authorized Dealer within two (2) days of the appearance of a defect.
Owner must bring Product, including any defective part therein, to Dealer promptly after the appearance
of the defect, and in any event, within the warranty period, and must provide Dealer with reasonable op-
portunity to repair the defect. The expenses of transporting Product to and from Dealer for warranty ser-
vice are to be borne by the owner.
If the Product has not previously been registered, the owner may also be required to present proof of pur-
chase to Dealer for warranty repairs. Owner is required to sign the repair/work order prior to the start of
the repair in order to validate the warranty repair.
All parts replaced under this warranty become the property of BMCA.
5. WHAT BOMBARDIER MOTOR CORPORATION OF AMERICA WILL DO
Bombardier Motor Corporation of America’s obligations under this warranty are limited to, at its sole dis-
cretion, repairing or replacing parts of Product found to be defective in material or workmanship, in the
reasonable judgment of BMCA. Such repair or replacement of parts will be done without charge for parts
and labor, at any authorized Dealer. BMCA's responsibility is limited to making the required repairs or re-
placements of parts with new or BMCA-certified re-manufactured parts. No claim of breach of warranty
shall be cause for cancellation or rescission of the sale of Product to owner.
In the event that warranty service is required outside of the fifty United States or Canada, owner will bear
responsibility for any additional charges due to local practices and conditions, such as, but not limited to,
freight, insurance, taxes, license fees, import duties, and any and all other financial charges, including
those levied by governments, states, territories and their respective agencies.
BMCA reserves the right to improve, modify or change Products from time to time without assuming any
obligation to modify Products previously manufactured.
6. EXCLUSIONS – The following are not warranted under any circumstances:

• Replacement of parts due to normal wear and tear;
• Routine maintenance parts and services including but not limited to: maintenance requirements, engine
and lower unit oil changes, lubrication, valve and linkage adjustments and replacement of fuses, zinc
anodes, thermostats, timing belts, starter motor bushings, trim motor brushes, filters, propellers, propel-
ler bushings and spark plugs;
• Damage caused by improper or lack of installation, maintenance, winterization and/or storage, failure
to follow the procedures and recommendations in the Operator's Guide;
• Damage resulting from removal of parts, improper repairs, service, maintenance, or modification, or use
of parts or accessories not manufactured or approved by BMCA, which in its reasonable judgment, are
either incompatible with Product or adversely affect its operation, performance, or durability, or resulting
from repairs done by a person that is not an authorized Dealer;
• Damage caused by abuse, misuse, abnormal use, neglect, racing, improper operation or operation of
the Product in a manner inconsistent with the recommended operation described in the Operator's
Guide;
• Damage resulting from external damage, accident, submersion, water ingestion, fire, theft, vandalism
or any act of God;
• Operation without proper fuel, oil or lubrication, or with fuels, oils or lubricants which are not suitable for
use with the Product (see the Operator's Guide);
• Damage resulting from rust or corrosion;
• Damage caused from cooling system blockage by foreign material;
• Damage resulting from sand or debris in the water pump;
• Cosmetic or paint changes due to exposure to the elements.
This warranty will be voided in its entirety and rendered null and void where:
• Product has been altered or modified in such a way so as to adversely affect its operation, performance
or durability, or change its intended use, horsepower or emission levels; or
• Product is or has been used for racing at any point, even by a prior owner.
7. LIMITATIONS OF LIABILITY
ALL WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRAN-
TY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURA-
TION TO THE LIFE OF THE EXPRESS LIMITED WARRANTY.
ALL INCIDENTAL, CONSEQUENTIAL, DIRECT, INDIRECT OR OTHER DAMAGES OF ANY KIND

ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY INCLUDING, BUT NOT LIMITED TO:
expense for gasoline, expense for transporting Product to and from Dealer, removal of Product from a
boat and reinstallation, mechanic's travel time, in-and-out of water charges, slip or dock fees, trailering or
towing, storage, telephone, cell phone, fax or telegram charges, rental of a like or replacement Product or
boat during warranty services or down time, taxi, travel, lodging, loss of or damage to personal property,
inconvenience, cost of insurance coverage, loan payments, loss of time, loss of income, revenue or prof-
its, or loss of enjoyment or use of Product.
SOME STATES, PROVINCES, OR JURISDICTIONS DO NOT ALLOW FOR THE DISCLAIMERS, LIM-
ITATIONS OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, OR OTHER EXCLUSIONS IDENTI-
FIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU
SPECIFIC RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH MAY VARY FROM
STATE TO STATE, OR PROVINCE TO PROVINCE.
No distributor, Dealer or any other person is authorized to make any affirmation, representation or war-
ranty regarding Product other than those contained in this limited warranty and, if made, shall not be en-
forceable against BMCA. BMCA reserves the right to modify this warranty at any time, being understood
that such modification will not alter the warranty conditions applicable to the Products sold while this war-
ranty is in effect.
8. TRANSFER
If the ownership of Product is transferred during the warranty coverage period, this warranty shall also be
transferred and be valid for the remaining coverage period provided that the former or new owner promptly
contacts BMCA or Dealer and gives the name and address of the new owner.
9. CONSUMER ASSISTANCE
• In the event of a controversy or dispute in connection with this BMCA limited warranty, BMCA recom-
mends that you first try to resolve the issue at the dealership level by discussing the issue with Dealer's
service manager or owner;
• If further assistance is required, please contact the Bombardier Motor Corporation of America Customer
Support Services, 250 Sea Horse Drive, Waukegan, IL 60085, 1-847-689-7090.
Revision March 2004

* Engines sold in Canada are distributed and serviced by Bombardier Recreational Products Inc.
BOMBARDIER MOTOR CORPORATION OF AMERICA
LIMITED WARRANTY FOR 2005 JOHNSON 2-STROKE OUTBOARD ENGINES
SOLD OUTSIDE THE UNITED STATES AND CANADA
For a copy of the Limited Warranty, see your Bombardier Motor Corporation of America (“BMCA”) distrib-
utor/dealer authorized to distribute Johnson 2-stroke products in the country in which the sale occurs.
If further assistance is required, please contact Bombardier Motor Corporation of America Customer Sup-
port Services, 250 Sea Horse Drive, Waukegan, Illinois, 60085, or the affiliate of BMCA where the Product
was registered for warranty.
NOTES
FEATURES
17
16
1
15
29
14 13
12
2 11
9
5
10
4
8
6
000101
5 18
Item Description Item Description

(1)
1 AC Lighting Inlet 10 Clip and Lanyard Assembly
2 Water Pump Indicator 11 Steering Handle and Twist-GripTM Throttle
3 Tilt/Run Lever 12 Idle Speed Adjustment Knob
4 Angle Adjusting Rod 13 Stop Button/Emergency Stop Switch
5 Anticorrosion Anode 14 Primer Knob
6 Lubricant Drain/Fill Plug 15 Shift Lever
7 Lubricant Level Plug 16 Starter Handle
8 Stern Brackets 17 Manual Starter Housing
9 Clamp Screws 18 Fuel Tank (2)
(1) Use with Optional Kit

(2) Not supplied in all marketing areas
32
33 31
30
20
21
34
29
22
23
24
28
25 27
26
19 000102
Item Description Item Description

19 Installation Hardware 27 Trim Tab
20 Fuel Connector 28 ECI Label
21 Emergency Restart Clip Storage 29 Engine Cover Latch
22 Tilt Support Bracket 30 Spark Plugs
23 Steering Friction Adjustment Screw 31 Water Pressure Tap
24 Model and Serial Number Plate 32 Lifting Eye
25 Water Intakes 33 Fuel Pump Filter
(2)
26 Propeller 34 Emergency Start Cord
ENGINE SPECIFICATIONS
40 Model
Displacement 45 cu. in. (737 cc)
Engine Type Two-Cycle, In-line, 2 Cylinder
Loop-Charged
Full Throttle Operating Range 4500 to 5500 RPM
(1)
Power 40 HP (29.34 kw) @ 5000 RPM
Idle RPM in Gear (2) 800 ± 30
(2)
Ignition Timing –Idle 1° ± 1°
W.O.T. 19° ± 1°
Emission Control System: EM (Engine Modification)
per SAE J1930 (2)
Fuel Requirements (2) 87 Pump Posted AKI (90 RON) – Refer to Fuel and Oil
Fuel/Oil 50:1
Ignition Features S.L.O.W.™ (Speed Limiting Overheat Warning)
(2)
Spark Plug Refer to ECI Label
Torque 18 to 21 ft. lbs. (24 to 28 N·m)
AC Lighting (3) 60 watts AC @ 12 volts
Gearcase –Lubricant Evinrude/Johnson Ultra-HPF™ gearcase lubricant
Capacity 16.4 fl. oz. (485 ml)
Propeller (4) 12 1/4 x 15 in. (311 x 381 mm)
(4)
Fuel Tank Capacity – 6 U.S. gallons (22.7 liters)
Weight (5) R – 202 lbs. (91.6 kg)
RL – 207 lbs. (93.9 kg)
Transom Height R – 14 1/4 to 15 in. (368 to 381 mm)
RL – 19 1/2 to 20 in. (495 to 508 mm)
Sound at Driver’s Ear 84.7 dB(A)
(LpA) ICOMIA 39.94
Vibration at Tiller (arms) Less than 2.5 m/s2
(1) Rated following the standards of ICOMIA 28.83, ISO 3046, and NMMA.
(2) Emission Control Information.
(3) Available as optional kit.
(4) Not supplied in all marketing areas.
(5) Does not include propeller and fuel.
EMERGENCY STOP SWITCH An extra clip is provided — another person can in-
sert it in the stop switch and start the motor in an
emergency.
If equipped, the emergency stop switch is on the
steering handle. Use of the emergency stop feature
is highly recommended on all boats.
Connect the clip to the emergency stop switch. 1

Snap the lanyard to a secure place on the opera-
tor’s clothing or life vest — not where it might tear
away instead of activating the stop switch. Discon-
necting the clip and lanyard will stop the engine and
prevent the boat from becoming a runaway if the
driver moves beyond the range of the lanyard. If the
lanyard is too long, it can be shortened by knotting
or looping it. DO NOT cut or retie the lanyard.
1
1. Extra clip
WARNING
Avoid knocking or pulling the clip off the
stop switch during normal boating. The
resulting unexpected loss of forward
motion can throw occupants forward, caus-
2 ing injury.
Your emergency stop switch can be effec-
tive only when in good working condition.
1. Emergency stop switch At each outing, inspect clip and lanyard for
2. Clip cuts, breaks, or wear. Replace worn or dam-
aged parts.
Keep the lanyard free from obstructions and
entanglements.
At each outing, test the system’s operation.
With the engine running, remove the clip
from the switch by pulling the lanyard. If the
engine does not stop running, see your
Dealer.
FUEL AND OIL
FUEL Minimum Octane
Inside the U.S. 87 (R+M)/2 AKI

WARNING Outside the U.S. 90 RON
Gasoline is extremely flammable and highly Your outboard has been designed to operate using
explosive under certain conditions. Follow the above fuels; however, be aware of the follow-
the instructions in this section explicitly. ing:
Improper handling of fuel could result in The boat’s fuel system may have different require-
property damage, serious injury, or death. ments regarding the use of alcohol fuels. Refer to
the boat’s Owner Guide.
Always turn off the engine before fueling.
Alcohol attracts and holds moisture that can cause
Never permit anyone other than an adult to corrosion of metallic parts in the fuel system.
refill the fuel tank. Alcohol blended fuel can cause engine perfor-
Do not fill the fuel tank all the way to the top, mance problems.
or fuel may overflow when it expands due to IMPORTANT: Always use fresh gasoline. Gasoline
heating by the sun. will oxidize and weather; the result is loss of octane,
Remove portable fuel tanks from the boat volatile compounds, and the production of gum and
before fueling. varnish deposits which can damage the outboard.
Always wipe off any fuel spillage.

WARNING
Do not smoke, or allow open flames or
sparks, or use electrical devices such as Leaking fuel is a fire and explosion hazard.
cellular phones in the vicinity of a fuel leak All parts in the fuel system should be
or while fueling. inspected frequently and replaced if signs
of deterioration or leakage are found.
Always work in a well-ventilated area. Inspect the fuel system each time you
refuel, each time you remove the engine
cover, and annually.
Your outboard is certified to operate on unleaded
automotive gasoline with an octane rating equal to
or higher than that specified in Minimum Octane
chart. When using gasoline that contains MTBE or OIL
alcohol, follow these guidelines:
Using unleaded gasoline that contains methyl ter- Evinrude/Johnson XD25™ Formula outboard
tiary butyl ether (MTBE) is acceptable ONLY if the oil is recommended for your outboard. It con-
MTBE content does not exceed 15% by volume. tains a richer additive package than other TC-W3
Using alcohol-extended fuels is acceptable ONLY if oils, minimizing carbon build-up and deposits on
the alcohol content does not exceed: pistons and bearing surfaces. It provides 25%
greater detergency than minimum TC-W3 require-
10% ethanol by volume; or ments.
5% methanol with 5% cosolvents by volume Evinrude/Johnson brand oils are formulated to give
best engine performance while controlling piston
and combustion chamber deposits, providing supe-
rior lubrication and ensuring maximum spark plug
life.
If Evinrude/Johnson XD25 Formula outboard oil is
not available, you must use an NMMA-certified TC-
W3 oil such as Evinrude/Johnson direct injection oil
or Evinrude biodegradable outboard oil.
IMPORTANT: Failure to follow this recommenda-
tion could void the engine warranty if a lubrication-
related failure occurs.
14 - Fuel and Oil

ADDITIVES Portable Tank
Above and below 32° F (0°C), add one gallon of fu-
IMPORTANT: Only use fuel additives approved by el. Pour in required amount of oil. Add remaining fu-
BMCA for your outboard. Use of other fuel additives el. Install filler cap and tip tank gently to distribute
can result in poor performance or engine damage. oil.
Evinrude/Johnson 2+4 fuel conditioner will help
prevent gum and varnish deposits from forming in
fuel system components and will remove moisture
from the fuel system. It can be used continuously
and should be used during any period when your
engine is not being operated on a regular basis. Its
use will reduce spark plug fouling, fuel system icing,
and fuel system component deterioration.
FUEL/OIL RATIO
New Engine
During break-in, you must use a 25:1 (4% oil) fuel/
oil ratio in your fuel tank. Refer to Break-In (10
Hours).
Normal Operation Permanently Installed Tank
After break-in, the engine must be operated at a Above 32° F (0° C), pour oil slowly with the fuel as
50:1 (2% oil) fuel/oil ratio. tank is filled. Below 32° F (0° C), add one gallon of
High Performance fuel to a separate container. Pour in required
amount of oil. Install filler cap and tip container gen-
During high performance operation you must use a tly to distribute oil. Slowly pour oil/fuel mixture into
25:1 (4% oil) fuel/oil ratio in your fuel tank. tank with fuel as tank is filled.
MIXING FUEL AND OIL
Use the following chart and these guidelines to mix

oil with the engine’s fuel.
Ratio Fuel
6 U.S. Gallons 3 U.S. Gallons 1 Liter
50:1 16 fl. oz. oil 8 fl. oz. oil 20 ml oil
25:1 32 fl. oz. oil 16 fl. oz. oil 40 ml oil
Fuel and Oil - 15

FUEL SYSTEMS IMPORTANT: Before the first start-up of your
new engine:
• Read Engine Starting, Engine Stopping, and
Shifting and Speed Control.
WARNING • Check the gearcase lube level. Refer to Lubrica-
tion.
If your motor is equipped with a quick-dis- • Perform prelaunch checks of all equipment.
connect fuel hose, disconnect the fuel hose
from the motor and from the fuel tank when Launch the boat and start the engine according
the motor is not being used for a period of to the procedures in Engine Starting.
time. Disconnecting the hose will avert fuel • Verify water pump operation often. Look for a
leaks in the hose or at the engine. steady stream of water from the water pump indi-
cator. If the stream of water stops, shut off the en-
gine to prevent damage. Find and correct the
IMPORTANT: Fuel distribution hoses in the boat cause, or see your Dealer before you continue.
must deliver fuel at the rate of flow needed by the • Verify shift function by shifting into gear and ob-
engine. Minimum inside diameter of fuel hoses serving that the boat moves and that the move-
must be 5/16 in. (8 mm). ment is in the same direction as the shifter. Refer
Fuel systems with built-in tanks, particularly those to Shifting and Speed Control.
that include antisiphon valves and filter/primer • Change the RPM often. Avoid holding a throttle
units, may have restrictions that will not allow the setting longer than 15 minutes.
engine fuel pump to deliver sufficient fuel under all
conditions. This can result in a loss of performance 1. First 10 Minutes of Operation — Operate the
and possible engine damage. If a performance engine in gear at fast idle only.
problem exists, see your Dealer. 2. Next 50 Minutes — Operate engine in gear at
To avoid difficulty when restarting, never run the various speeds no faster than 3500 RPM.
engine with the fuel hose disconnected or run the DO NOT hold a constant throttle setting. Change
engine out of fuel. engine speed every 15 minutes.
With easy planing boats, use full throttle to quickly
BREAK-IN (10 HOURS) accelerate boat onto plane. Immediately reduce
throttle to one-half as soon as boat is on plane. BE
SURE boat remains on plane at this throttle setting.
IMPORTANT: Follow this procedure to protect your
new outboard during its initial hours of operation. 3. Second Hour — Use full throttle to accelerate
Careful break-in allows internal engine components boat onto plane, then reduce throttle setting to
to “seat” properly, resulting in maximum engine per- three-quarters. BE SURE boat remains on plane at
formance. this throttle setting.
Failure to carefully follow the break-in procedures At intervals, apply full throttle for periods of one to
can result in engine damage. two minutes, returning to three-quarters throttle for
During break-in, you must use extra oil. The fuel/oil a cooling period.
ratio for the first 10 hours of operation must be 25:1 Change engine speed every 15 minutes.
(4% oil). The fuel/oil ratio during normal operation,
after break-in, must be 50:1 (2% oil). 4. Next Eight Hours — Avoid continuous full
throttle operation for extended periods.
Perform the 10-Hour break-in procedure with the
boat and engine in the water, using an appropriate Change engine speed every 15 minutes.
propeller. DO NOT exceed recommended maximum engine
DO NOT perform break-in using a flushing device. RPM. Refer to Engine Specifications.
DO NOT start-up or run the engine out of the water.
DO NOT leave a running engine unattended.
16 - Fuel and Oil

ENGINE STARTING
BEFORE START-UP
DANGER
Review and follow Break-In (10 Hours) if the en-
DO NOT run the engine indoors or without gine is new.
adequate ventilation or permit exhaust You MUST supply water to the engine before at-
fumes to accumulate in confined areas. tempting to start it. Engine damage can occur
Engine exhaust contains carbon monoxide quickly. Refer to Engine Overheating or Flushing.
which, if inhaled, can cause serious brain
damage or death. Move tilt/run lever to RUN. Be sure the engine is in
normal operating position. Refer to Tilting.
WARNING 1
The engine cover is a machinery guard. DO
NOT operate your outboard with the cover
off unless you are performing maintenance, 2
and then be careful to keep hands, hair, and
clothing clear of all moving parts. Contact
with moving parts could cause injury.
DANGER
1. RUN position
Contact with a rotating propeller is likely to 2. TILT position
result in serious injury or death. Assure the
engine and prop area is clear of people and
objects before starting engine or operating WARNING
boat. Do not allow anyone near a propeller,
even when the engine is off. Blades can be Your motor has “impact protection” and
sharp and the propeller can continue to turn “reverse lock” only when the tilt/run lever is
even after the engine is off. Always shut off in RUN position. If operated with the tilt/run
the engine when near people in the water. lever left in TILT position, the motor could
tilt into the boat suddenly, causing loss of
control or serious injury.
Connect the fuel hose to the fuel connector.
1. Fuel hose connector

2. Fuel connector
Engine Starting - 17
If equipped, open vent screw on fuel tank’s filler
cap.
WARNING
Squeeze fuel primer bulb, outlet end up, until firm.
Always shift to NEUTRAL before starting
the engine to prevent sudden boat move-
ment, which can cause injury.
2
1
Twist the throttle grip to START.
1. Fuel tank operable vent

2. Fuel primer bulb
If equipped, attach the clip and lanyard assembly to

the emergency stop switch. Snap the lanyard to se-
cure place on your clothing or life vest.
1. START
IMPORTANT: Avoid engine damage. DO NOT run
engine above START in NEUTRAL.
Start-up (Cold Engine)
WARNING
Start engine with shift lever in NEUTRAL.
1 Attempting to manually start the engine
while in gear may damage parts or cause
the start-in-neutral-only feature to become
inoperative.
1. Emergency stop switch
Twist throttle grip to SHIFT or slower. Pull primer knob through its full stroke twice and re-
turn to the warm-up (color line showing) position. If
the motor does not start after a few rope pulls,
prime again.
1. SHIFT
Move the shift lever to NEUTRAL. Refer to Shifting

and Speed Control. 1. Primer knob
18 - Engine Starting
The manual primer has two functions. It primes the Start-up (Warm Engine)
engine for quick cold starting and provides extra
fuel for warm-up. Push primer in to RUN (no color Follow Cold Engine procedure except warm en-
line showing) when motor is sufficiently warmed up. gines do not normally require priming. If your en-
gine fails to start, then use the primer.
While seated, grasp the starter handle and pull
slowly until starter engages, then pull hard. Repeat,
if needed, until motor starts. To prevent damage to ENGINE STOPPING
starter assembly, allow starter cord to rewind be-
fore releasing starter handle. If motor does not Twist the throttle grip to SHIFT position or slower.
start, refer to Trouble Check Chart.
Move shift lever to NEUTRAL.
Press the STOP button until the engine stops run-
ning. If equipped, close the vent screw on the fuel
tank’s filler cap.
2
1. Starter handle 1
2. NEUTRAL
IMPORTANT: If your outboard does not react nor-

mally to this starting procedure or fails to start, refer 1. STOP button
to Trouble Check Chart.
To avoid difficulty when restarting, never stop the
After Engine Starts engine by running it with the fuel hose disconnected
or otherwise running it out of fuel.
Check the water pump indicator. A steady stream of
water indicates the water pump is working. If a
steady stream of water from the water pump indica-
tor is not visible, stop the engine. Refer to Engine
Overheating.
1) Push primer in to RUN (no color line showing)
when motor is sufficiently warmed up.
2) Allow the engine to idle in NEUTRAL for about
five minutes to warm up before shifting.
IMPORTANT: To avoid engine damage, after start-

up, do not exceed one-quarter throttle (less than
2000 RPM) in NEUTRAL for extended periods of
time.
SHIFTING AND SPEED CONTROL Speed Control
With the engine running, twist the throttle grip:
IMPORTANT: Carefully check the function of all • Counterclockwise to increase speed; or
control and engine systems before leaving the • Clockwise to decrease speed.
dock. DO NOT shift the engine into FORWARD or
REVERSE while it is shut OFF.
Shifting 1
With the engine running, twist the throttle grip to
SHIFT or slower.
Move the shift lever briskly and decisively to FOR-
WARD or REVERSE.
3 2 1. Decrease speed
2. Increase speed
EMERGENCY STARTING
If the starter cord breaks or the starter fails, your en-

1 gine can be started using a piece of the starter cord
or a 1/4 in (6 mm) cord about 4 ft. (1.2 m) long.
1. Shift lever
2. FORWARD
3. REVERSE WARNING
When using Emergency Starting proce-
WARNING dures, the start-in-neutral-only feature is
inoperative. Make sure shift lever is in NEU-
Do not operate motor in REVERSE with the TRAL position to prevent injuries from
tilt/run lever in TILT. Motor may tilt out of the unexpected boat movement when the
water, resulting in loss of control. engine starts.
The engine cover is a machinery guard. To
prevent injury from moving engine compo-
IMPORTANT: Before moving the shift lever, reduce nents, keep hands, clothes, and hair clear of
throttle to SHIFT speed or slower, then pause until powerhead.
motor slows to idle speed and boat has slowed.
Prevent electric shock by keeping clear of
the ignition coils and spark plug leads when
the motor is being started or is running.
Shock can cause serious personal injury
under certain conditions.
DO NOT turn flywheel by hand. Use starter
cord only.
20 - Engine Starting
Be sure:
• Tilt/run lever is in the RUN position
• Engine is in normal operating position.
• Fuel hose primer bulb is firm.
• Shift lever is in NEUTRAL.
• Twist-Grip throttle is at START. 1
Remove engine cover.
1. Starter handle bracket screws
Hook the knot of your emergency start cord into the

notch on the flywheel. Wind the cord clockwise in
the flywheel ridge.
1
2
If your motor has a starter lockout cable, remove
the screw and cable clamp and slide. Pull the cable
from its seat on the starter housing and remove the
three screws from the housing.
3 1
2
1. Knot
2. NEUTRAL
While seated, pull hard on emergency starting cord

to start motor.
After the motor starts, run it at less than 2000 RPM
in NEUTRAL for two minutes, then reduce speed to
an idle.
Do not attempt to replace engine cover while en-
1. Cable clamp gine is running.
2. Slide If equipped, snap emergency stop switch lanyard to
3. Housing screws secure place on clothing. Proceed to nearest land-
ing for service.
Remove the two screws from the starter handle
bracket. Lift starter assembly from engine.
FUEL ECONOMY
The economy throttle position can save fuel, de-

pending on boat load and hull design. When boat
reaches top speed, throttle back from FULL
SPEED. You will save fuel without a noticeable loss
of speed.
OPERATION
Operation Underway
DANGER The Touch-Trim feature allows the operator to trim
the motor (change motor angle) while underway to
DO NOT run the engine indoors or without improve acceleration, speed, and to meet changing
adequate ventilation or permit exhaust water conditions.
fumes to accumulate in confined areas. Boat performance and trim position will differ de-
Engine exhaust contains carbon monoxide pending on the type of boat, load, propeller, and op-
which, if inhaled, can cause serious brain erating conditions. The best ride, fuel economy,
damage or death. performance, and speed is determined by the oper-
ator’s use of the Touch-Trim feature.
The effect of the maximum bow-up and bow-down
positions will be relatively the same for most appli-
DANGER cations, however, the bow position that is best for
your operating conditions could be at any trim set-
ting between the maximum bow-up and bow-down
Contact with a rotating propeller is likely to positions.
result in serious injury or death. Assure the
engine and prop area is clear of people and The boat will be properly trimmed when the trim an-
objects before starting engine or operating gle is adjusted to provide a bow position that results
boat. Do not allow anyone near a propeller, in the best boat performance for your particular op-
even when the engine is off. Blades can be erating conditions.
sharp and the propeller can continue to turn
even after the engine is off. Always shut off IMPORTANT: Make sure the boat remains on
the engine when near people in the water. plane during the following steps.
Bow-Up
To move the boat’s bow UP:
MANUAL TRIM • Slowly start to reduce the engine throttle setting.
• While boat speed is being reduced, place the tilt/
The Touch-TrimTM feature allows the operator to run lever in the TILT position. The motor will au-
trim the motor (change motor angle) without manu- tomatically start to tilt up.
ally tilting the motor. This feature can be operated • Place the tilt/tun lever in RUN to lock the motor in
at idle speed or while the boat is underway. the desired bow-up position.
To become familiar with the Touch-Trim feature, it
is recommended you make test runs at moderate
speeds and various trim positions. Note the time it
takes the boat to plane, the boat speed, ride, and
action.
1
Operation at Idle Speed
Make sure the engine is at idle speed and the shift
handle is in NEUTRAL.
Place tilt/run lever in the TILT position. 2
To tilt motor down:
• Move shift lever to FORWARD. The motor will tilt
down until the tilt/run lever is placed in RUN, or
the motor reaches the maximum “down” position.
1. Bow-up
To tilt motor up: 2. Maximum trim
• Move shift lever to REVERSE. The motor will tilt
itself up until the tilt/run lever is placed in RUN.
IMPORTANT: Care must be taken when tilting the
motor up. The water intakes MUST be completely
submerged while engine is running.
22 - Operation
You can now resume operation in a manner suit- Bow-Down
able for the new trim position.
To move the boat’s bow DOWN:
IMPORTANT: DO NOT operate the motor if the wa- • Make sure the engine is at a constant throttle set-
ter intakes are not completely submerged. Motor ting.
may overheat and water pump may be damaged. • Gradually move the tilt/run lever to the TILT posi-
The bow-up position (maximum trim) will give the tion. The motor will automatically start to tilt down.
best fuel economy and highest top speed. The bow- • Place the tilt/tun lever in RUN to lock the motor in
up position is normally used for cruising or running the desired bow-down position.
at full speed.
Operating Conditions:
In the bow-up position, the boat may tend to turn to
the left. If this condition exists, it should be compen-
sated for with the operator’s steering, or the trim tab 1
should be adjusted, if this is your most commonly
used trim position. Refer to Adjustments.
In this position, the boat’s bow will want to raise
clear of the water. Excessive bow-up trim may
cause propeller ventilation resulting in propeller
slippage. 2
WARNING
1. Bow-down
When operating in rough water or crossing 2. Minimum trim
a wake, excessive bow-up trim may result in
the boat’s bow suddenly rising skyward, You can now resume operation in a manner suit-
possibly ejecting occupants. able for the new trim position.
Operating Conditions:
In the bow-down position (minimum trim), the boat
WARNING may tend to turn to the right. If this condition exists,
it should be compensated for with the operator’s
Some boat/motor/propeller combinations steering, or the trim tab should be adjusted (if this is
may encounter boat instability and/or high your most commonly used trim position). Refer to
steering torque when operated at high Adjustments.
speed at or near the motor’s trim range lim- When the motor is trimmed to full bow-down posi-
its (full bow-up or bow-down). Boat stability tion, the boat’s bow will tend to go deeper into the
and steering torque can also vary due to water (plow).
changing water conditions. If any adverse
conditions occur, reduce throttle and/or
adjust trim angle to maintain control. If you WARNING
experience boat instability and/or high
steering torque, see your Dealer to correct If the bow of the boat plows the water at
these conditions. high speeds, the boat may bow steer or spin
suddenly, possibly ejecting occupants.
Operation - 23
TRAILERING Grasp tilt grip on engine cover and tilt or lower mo-
tor to any position desired.
Trailer your boat with the motor in a vertical posi-

tion. If your trailer does not provide adequate road 1
clearance, the motor can be trailered by using the
tilt support or an accessory trailering bracket. Refer
to Tilt Support.
IMPORTANT: Whenever using the tilt support or an
accessory trailering bracket, the motor must be re-
strained. Bouncing during transport will damage the
motor and boat’s transom.
TILTING
IMPORTANT: Use the tilt grip to tilt your motor; not

the steering handle. 1. Tilt grip
Move tilt/run lever to TILT position.
Move tilt/run lever to RUN to lock motor in the se-
lected position.
2 1
1
2
1. TILT position
2. RUN position
1. RUN position
2. TILT position
Leave the tilt/run lever in RUN when launching boat

with the motor in the full TILT position, or if it will not
be used for a period of time. However, if it is neces-
sary to leave the motor tilted, use the tilt support.
Refer to Tilt Support.
24 - Operation
TILT SUPPORT MOTOR ANGLE ADJUSTMENT
Engage Motor should be perpendicular to the water when

the boat is underway at full speed. This adjustment
Raise the motor to full TILT position. Refer to Tilt- can only be determined by water testing the boat.
ing. Rotate the tilt support lever to the down posi- Set angle adjustment for your normal load.
tion. Place motor in full tilt position. Refer to Tilt Sup-
port.
• Remove one of the locknuts from angle adjusting
rod.
• Move angle adjusting rod.
• Install locknut and tighten securely.
DR4245
1. Tilt support lever – down position
Lower motor until tilt support rests solidly on stern

brackets. 1 2
Move tilt/run lever to RUN position.
1. Angle adjustment rod and locknut
Disengage 2. Alternate angle adjustment rod locations
Move tilt/run lever to the TILT position. Raise motor
IMPORTANT: DO NOT reuse locknuts more than
to full TILT position. three times. See your Dealer for replacements.
Rotate the tilt support lever to the up position.
1. Tilt support lever – up position
Lower motor to normal operating position.

Move tilt/run lever to RUN position.
Operation - 25
PROPELLER SELECTION Outboard — Running
To select the correct propeller for your boating ap-

plication, your boat and motor MUST be water test- WARNING
ed. See your Dealer for assistance.
Prevent injury from contact with rotating
Refer to Propeller, before removing or installing propeller; remove the propeller before
propeller. flushing.
IMPORTANT: The correct propeller for your boat,
under normal load conditions, will allow the engine
to run near the midpoint of the RPM operating 1) Place the engine in vertical position in a well-
range at full throttle. Refer to Engine Specifica- ventilated area with good drainage.
tions. 2) Install flushing device and garden hose.
3) Place the shift lever in NEUTRAL with the
propeller removed.
MOORING 4) Start the water — keep pressure between 20
You may moor your boat with the motor’s gearcase to 40 psi (140 to 300 kPa).
out of the water by using its tilt feature. Refer to Tilt
Support.
FLUSHING
DANGER
DO NOT run the engine indoors or without
adequate ventilation or permit exhaust
fumes to accumulate in confined areas.
Engine exhaust contains carbon monoxide
which, if inhaled, can cause serious brain
damage or death.
1. Flushing device
See your Dealer for a flushing device designed to fit 2. Water pump indicator
your engine. Follow manufacturer’s instructions for
installing and using it. 5) Start the engine — run it at idle only and
flush it for at least five minutes. Check the
water pump indicator. A steady stream of wa-
ter must flow. If it does not, shut OFF the en-
gine and investigate. Refer to Engine
Overheating.
6) Leave the outboard in vertical position long
enough to completely drain the powerhead.
26 - Operation
ENGINE OVERHEATING IF the S.L.O.W. protection system activates and the
stream from the water pump indicator becomes in-
termittent or stops, reduce speed to idle and:
IMPORTANT: Do not run your engine — even for a
brief start-up — without supplying water to it. Refer • Shift to NEUTRAL;
to Flushing. • SHUT OFF the engine;
While boating, the engine’s water intakes must stay • Tilt the motor up;
completely submerged and unobstructed. Observe • Clean the intake screens of any blockage;
proper transom height and trim angle. While the en- • Clean the water pump indicator of any blockage;
gine is running, the engine’s water pump indicator • Lower the motor; and
must discharge a steady stream of water. Check • Restart the engine and run at idle.
the indicator often, especially when operating in IF cleaning the screens and indicator does not re-
weeds, muddy and debris-laden water, at extreme store the water pump indicator’s steady discharge,
trim angles, or in shallow-water drive (if equipped). SHUT OFF the engine and do not attempt to oper-
ate it. See your Dealer.
IF cleaning the screens and indicator does restore
the water pump indicator’s steady discharge, you
might have to run for two minutes in NEUTRAL to
allow the engine to cool.
IMPORTANT: You must restore cooling to the en-
gine to avoid serious engine damage.
After any overheat, have your Dealer:
Torque the cylinder head screws.
Inspect the water pump for excessive wear or dam-
age.
Inspect the thermostats.
Inspect the engine for leaks.
1. Water intake screens
2. Water pump indicator
If the engine overheats, the S.L.O.W. (Speed Limit-
ing Overheat Warning) protection system will im-
mediately limit the engine speed to 2000 RPM. If
the engine was running faster than 2000 RPM
when the S.L.O.W. system activated, it will shake
noticeably.
To RESET the S.L.O.W. protection system, the en-
gine must be shut OFF and the cooling temperature
restored.
Operation - 27
IMPACT DAMAGE
Your engine has a shock absorption system de-

signed to help withstand damage from impact with
underwater objects at low to moderate speeds.
However, high speed impacts with rigid underwater
objects like pilings or boulders can be beyond the
capability of the absorption system. Such impacts
can result in serious damage to your engine and in-
jury to boat occupants from the engine or its parts
entering the boat. Occupants can also be ejected or
injured by falling against portions of the boat as a
result of rapid deceleration following impacts. When
boating in unfamiliar, shallow or debris-laden wa-
ters, seek information on safe boating areas and
navigation hazards from a reliable local source. Re-
duce your speed and keep a sharp lookout!
If you hit any object, stop immediately and examine
the engine for loosening of attaching hardware and
clamp screws, if equipped. Inspect for damage to
swivel and stern brackets, steering components,
and components in the area of impact. Also, exam-
ine the boat for structural damage. Tighten any
loosened hardware. If the collision occurred in the
water, proceed slowly to harbor. Before boating
again, have your Dealer thoroughly inspect all com-
ponents.
WARNING
Failure to inspect for damage could result in
sudden, unexpected component failure,
loss of boat control, and personal injury.
Unrepaired damage could reduce your boat
The engine’s shock absorption system does not and engine’s ability to resist future impacts.
work while operating in reverse. If you back into an
object, either in the water or while trailering, your
boat and engine can be seriously damaged.
STORING
To avoid difficulty when restarting, never run the

engine with the fuel hose disconnected or run the
engine out of fuel.
If you must tilt the motor to remove it from the water,
lower it and allow the cooling system to drain com-
pletely as soon as you clear the launch area.
Between uses, store your motor in a vertical posi-
tion.
For recommendations on extended periods of stor-
age, refer to Off-Season Storage.
28 - Operation
SPECIAL OPERATING CONDITIONS High Altitude
If you boat at altitudes above 3000 ft. (900 m), your
Salt Water engine might benefit from a lower pitched propeller,
different carburetor calibration, or both. See your
Flush the engine internally after use in salt, pollut- Dealer.
ed, or brackish water to help prevent mineral de-
posits from clogging cooling passages. Refer to IMPORTANT: To avoid permanent powerhead
Flushing. damage, be sure that an engine modified for high
altitude operation is properly identified and returned
During use in salt or brackish water, additional an- to original calibration and propeller size if operated
odic protection for the boat and outboard may be re- below 3000 ft. (900 m).
quired.
During long periods of mooring, tilt the gearcase out
of the water — except in freezing temperatures. Shallow Water
Upon removal from salt water, leave it in a vertical
position until its cooling system has drained. IMPORTANT: Serious engine damage will occur if
the gearcase is allowed to drag on the waterway
bottom.
Weedy Water
Weeds block water intakes and cause your out- Freezing Weather
board to overheat. Weeds on the propeller create
vibration and reduce boat speed. DURING operation in freezing weather, keep the
gearcase submerged at all times.
Run at slow speeds and in REVERSE frequently to
clear weeds from the propeller and water intakes. Upon removing your motor from the water, leave it
Check the water pump indicator often. in a vertical position until its cooling system is
drained.
If REVERSE operation does not clear away weeds,
SHUT OFF the engine. Remove weeds from pro- IMPORTANT: Water that has leaked into the gear-
peller area and water intakes before operating at case, or remained in the cooling system or other
higher speed. components can freeze, causing serious engine
damage.
Boat Bottom and Engine External Finish
The condition of your boat’s bottom affects perfor-
Submerged Engine
mance. A covering of marine growth reduces If your engine has been under water, have it ser-
speed. For maximum performance, keep the boat’s viced immediately upon recovery. If immediate
running surface clean by wiping it dry after each use service is unavailable, resubmerge it in fresh water
and washing it occasionally. to avoid prolonged exposure to the atmosphere.
After operating your outboard, rinse it with fresh wa- After submersion, all boat and engine electrical, fu-
ter and wipe it dry. Apply Evinrude/Johnson anti- el, and oiling systems must be inspected for signs
corrosion spray to any surface subject to corrosion, of water intrusion. Your Dealer should perform this
but avoid the anticorrosion anode(s). service.
Periodically, wash the entire boat and outboard with
soapy water and apply a coat of automotive wax. Under Tow
Leave the engine cover in place when washing the
outboard. Should you require a tow from another boat:
• Shift your engine to NEUTRAL;
• Tilt its gearcase out of the water; and
• Off-load all persons into another boat.
Keep towing speed slower than planing speed.
Operation - 29
MAINTENANCE
Maintenance, replacement, or repair of the OFF-SEASON STORAGE
emission control devices and systems may be
performed by any marine SI (spark ignition) en-
gine repair establishments or individual. You must protect against natural environmental
conditions that can be damaging to an outboard
motor. Temperature and humidity changes while
WARNING your outboard motor is not in use can cause corro-
sion of internal engine parts when they are not pro-
tected. Fuel remaining in your fuel tank and in the
Only perform service procedures which are engine will oxidize and weather which can result in
detailed in this Operator’s Guide. Attempt- loss of octane and can cause gum deposits in the
ing to perform maintenance or repair on fuel system. Your warranty does not cover engine
your outboard if you are not familiar with failure caused by these conditions. We strongly rec-
the correct service and safety procedures ommend that you have your Dealer prepare your
could cause injury or death. outboard for the off-season.
To do the off-season storage preparations yourself,
gather the supplies and perform the following steps.
Tampering with the carburetor to change horse-
power or modify emission levels beyond factory 2+4 fuel conditioner
settings or specifications will void the product war- Triple-Guard grease
ranty. Ultra-HPF gearcase lubricant
Storage Fogging Oil spray can
10-HOUR INSPECTION Stabilize the engine’s fuel supply with 2+4 fuel con-
ditioner during the last hours of operation to ensure
After 10 hours of operation, your new engine will be proper stabilization, following instructions on the
broken in and its mechanical parts will have seated. container for mixture. Be sure to run the engine
At that time, all systems should be checked and any long enough for the treated fuel to reach the en-
adjustments needed should be made. gine.
Your Dealer will perform this 10-Hour Inspection at
your request and expense (based on local rates),
according to what your engine needs — refer to En- WARNING
gine Maintenance and Inspection Schedule, 10-
Hour Inspection for a partial list. Prevent injury from moving engine compo-
nents. Before starting the engine:
Follow consistent preventive maintenance by hav-
ing your Dealer check and service your engine Shift it to NEUTRAL.
once a year or after each 100 hours of operation,
whichever comes first. Keep hands, clothes, and hair clear of pow-
erhead.
Remove the propeller if you use a flushing
device.
IMPORTANT: Provide water supply to the engine

and start it. Run the engine at idle only.
To run the engine on a flusher, refer to Flushing.
To avoid difficulty when restarting, never run the
engine with the fuel hose disconnected or run the
engine out of fuel.
30 - Maintenance
Storage Fogging Oil — Following instructions on PRE-SEASON SERVICE
the can, fog the engine.
Ignition, oil, and fuel systems — Check for mis- Remove your outboard from storage and prepare it
placed leads and damaged or deteriorated parts. for a season of reliable service by performing a gen-
Be sure starter solenoid terminal boot and all con- eral check and a few preventive maintenance pro-
nectors are in place. cedures.
Examine all loosened or removed hardware and
Fuel filter — Clean. any steering, throttle, and shift systems. Replace
Screws, bolts, nuts — Tighten any that are damaged or missing parts with Evinrude/Johnson
loose. Genuine Parts or equivalent.
Propeller — Remove and examine. If damaged,

see your Dealer. Clean the propeller shaft and lubri- WARNING
cate it. Refer to Propeller.
Failure to carefully reattach the outboard
Lubrication — Refer to Lubrication to drain and and its control systems with factory-speci-
refill the gearcase and for lubricating points on the fied hardware can result in sudden, unex-
engine. pected loss of boat control.
Touch up painted surfaces and wax the engine’s
exterior. Store the engine on the boat (or an engine
stand) in a vertical, self-draining position. With the propeller removed, check the gearcase for
IMPORTANT: Never place the gearcase higher leakage. If leakage is evident, the gearcase seals
than the powerhead. Any water remaining in the ex- should be replaced. See your Dealer.
haust passages can run into the cylinders and Anticorrosion anodes — Check condition. Refer
cause serious damage. to Anticorrosion Anodes.
If you remove an "installed" engine, examine all Install the propeller unless you will run the engine
hardware you loosened or removed from the en- on a flusher for your pre-season servicing. If so, in-
gine and its steering, throttle, and shift systems. stall the propeller after you shut OFF the engine
Replace damaged or missing parts with Evinrude/ and disconnect the flusher. Refer to Flushing.
Johnson Genuine Parts, or equivalent.
Refer to Propeller to install the propeller.
Portable fuel tank — Disconnect the hose from
the tank. Remove the hose from the engine if the fit-
ting is a quick-disconnect. If not, and the hose is se- WARNING
cured to the engine, leave it connected. Secure the
hose to protect it. Prevent injury from contact with rotating
propeller; remove the propeller before
flushing.
WARNING
Store fuel tanks in a well-ventilated area, Top off fuel tank with fresh fuel.
away from heat and open flame. Prevent
escape of liquid or vapors which could acci- Follow Engine Starting and start the engine. Let it
dentally ignite. Close the filler cap vent idle while you:
screw, if equipped. Be sure the discon- Observe running quality – if poor, refer to Trouble
nected fuel hose does not drip. Check Chart or see your Dealer.
Observe water pump operation. Water must flow
from the water pump indicator in a steady stream. If
it does not, shut OFF the engine and investigate.
Refer to Engine Overheating.
Stop the engine and check the fuel system for
leaks.
WARNING
Failure to check for fuel leakage could allow
a leak to go undetected, resulting in fire or
explosion.
Maintenance - 31
ADJUSTMENTS Steering Friction
The steering friction was set on your new motor be-
Idle Speed fore it left the factory. After the first 10 hours of ser-
vice, check to see that it is still correct. A slight drag
The idle speed adjusting knob is located at the end should be felt when turning the motor. If adjustment
of the steering handle. Before turning the knob, be is necessary, turn the adjustment screw:
sure the throttle is at SLOW and the motor has • Clockwise to increase friction; or
reached normal operating temperature:
• Counterclockwise to decrease friction.
• Increase idle speed – turn knob clockwise
• Decrease idle speed – turn knob counterclock-
wise
1
1. Steering friction adjustment screw
1. Idle speed adjusting knob WARNING

If your engine displays poor running quality at idle, DO NOT overtighten for “hands-off” steer-
ask your Dealer to perform the necessary adjusting. Reduced steering control could result.
ments.
Carburetor Trim Tab

High speed fuel calibration is maintained by the
fixed high speed jet in the carburetor. Fixed jets are WARNING
not adjustable.
Low speed fuel calibration is set at the factory with Improper trim tab adjustment can cause dif-
a range of adjustment provided. If your engine dis- ficult steering.
plays poor running quality at low speed or idle, ask
your Dealer to perform the necessary adjustments.
A propeller will generate steering torque when the
propeller shaft is not running parallel to the water’s
surface. The trim tab is adjustable to compensate
for this steering torque.
IMPORTANT: A single trim tab adjustment will re-
lieve steering effort under only one set of speed,
motor angle and load conditions. No single adjust-
ment can relieve steering effort under all speed,
motor angle and load conditions. If the boat pulls to
the left or right when its load is evenly distributed,
adjust the trim tab as follows:
32 - Maintenance
With the motor shut OFF, loosen the trim tab IMPORTANT: The recommended gear lubricants
screw. If the boat pulled to the right, move the rear include special additives for marine applications.
of the trim tab slightly to the right. If the boat pulled Do not use automotive gear lubricants, 2-stroke or
to the left, move the rear of the trim tab slightly to 4-stroke engine oil, or any other oil or grease for
the left. gearcase applications.
With motor in normal operating position:
1) Remove drain/fill plug and lubricant level plug
from side of gearcase and completely drain
gearcase of old lubricant.
2) Examine drained lubricant for metal filings,
milky appearance, or black color with burnt
odor. If old lubricant has any of those charac-
teristics, see your Dealer. If drained lubricant
is in good condition, continue.
3) Place tube of lubricant in drain/fill hole and fill
slowly until lubricant appears at lubricant lev-
el hole. See Engine Specifications for gear-
case capacity.
4) Install lubricant level plug before removing
tube from drain/fill hole. Drain/fill plug can
then be installed without loss of lubricant.
Tighten the trim tab screw to a torque of 18 to 20 ft. 5) Securely tighten both plugs.
lbs. (24 to 27 N·m).
Test the boat and, if needed, repeat the procedure
until steering effort is as equal as possible.
High motor installations — The trim tab might
be above the water when the motor is trimmed out.
Steering effort might increase. Steering effort will
be reduced if you trim the motor in and submerge 3
the trim tab.
LUBRICATION
Gearcase
Replace gearcase lubricant after first 10 hours of
operation. Check level and condition of lubricant af- 1. Drain/fill plug
ter next 50 hours of operation. Add lubricant if nec- 2. Lubricant level plug
essary. 3. Shift cradle screw – DO NOT REMOVE.
Thereafter, check level and condition of lubricant
every 50 hours. Replace lubricant every 100 hours
of operation or once each season, whichever oc-
curs first. Refill with Ultra-HPF gearcase lube. If not
available, Hi-Vis™ or other marine gearcase lube
can be used, however, long term durability may be
affected with continued use. See your Dealer.
Maintenance - 33
Lubrication Points
Refer to Engine Maintenance and Inspection
Schedule for lubrication frequency and recom-
mended lubricant.
1
1
1
1
1. Control shaft bushings, control lever bearings,
carburetor linkage, roller (cam follower)
1. Swivel bracket and tilt support
2
1 1 2
4 4
1
3
1. Throttle cable bushings
2. Spark advance linkage
1. Tilt tube
2. Steering handle fittings
3. Upper tilt cylinder rod
4. Clamp screws
34 - Maintenance
WATER PRESSURE
An optional water pressure gauge is recommended

to monitor cooling system pressures. Noticing
changes in water pressure can help prevent engine 3
overheating. The water pressure gauge must be 2
connected at the correct point to ensure the most 1
accurate pressure readings. Follow the installation
instructions included with the water pressure
gauge.
1. Cover
2. Filter
3. O-rings
Wash filter with clean solvent; blow dry.

Reinstall filter, keeping lip of filter screen toward
fuel pump body.
Install large O-ring in its groove in the cover and the
small O-ring around center post of pump body.
Replace O-rings if cut or damaged.
Reinstall cover.
FUEL PUMP FILTER Tighten cover screw securely; clean up spilled fuel.
Check for leaks – connect fuel hose to motor and
The fuel filter is located in the motor’s fuel pump. An squeeze primer bulb until firm.
authorized Evinrude/Johnson Dealer should ser-
vice the fuel filter.
WARNING
WARNING Failure to inspect your work could allow fuel
leakage to go undetected, becoming a fire
Prevent excessive fuel spillage by discon- or explosion hazard.
necting fuel hose from motor before disas-
sembly.
The filter is located under the inlet cover on the fuel

pump. To service, proceed as follows:
If portable tank is used, disconnect the fuel hose
from the motor before servicing the filter.
Loosen screw and remove the cover. Do not lose
O-rings.
Maintenance - 35
SPARK PLUGS PROPELLER
WARNING WARNING
The ignition system presents a serious When servicing the propeller, twist and
shock hazard. The primary circuit operates remove all spark plug leads so the engine
in excess of 250 volts; the secondary circuit cannot be started accidentally.
operates in excess of 25,000 volts. Use cau-
tion to avoid injury from shock or injury
resulting from your reaction to shock. Do IMPORTANT: Apply Triple-Guard grease to the en-
not handle primary or secondary ignition tire propeller shaft before installing the propeller. At
components while the engine is cranking or least annually, remove the propeller and check for
running. debris. Clean the shaft and regrease it before rein-
stalling a propeller.
Inspect spark plugs periodically. Replace if elec-

trodes are badly worn, insulators are cracked, or if Installation
they are badly fouled. Slide thrust washer onto shaft with shoulder facing
To remove spark plugs, twist and remove all spark aft.
plug leads. Unscrew spark plug from cylinder head. Slide propeller onto shaft, engaging the splines and
To install spark plugs, wipe spark plug seats clean seating it on the thrust washer.
with a clean rag. Install spark plugs finger tight, then Slide spacer onto the shaft and engage the propel-
tighten to specified torque. Refer to Engine Speci- ler shaft splines.
fications. Wedge a block of wood between the propeller
IMPORTANT: Avoid engine damage by installing blade and the antiventilation plate.
spark plugs into COOL cylinder head and not over-
tightening.
Before installing the spark plug lead, apply a light
coat of Triple-Guard grease to the ribbed portion of
the spark plug. This will help prevent corrosion be-
tween the spring terminal and the spark plug.
Install propeller nut and tighten to a torque of 120 in.

lbs. (14 N·m).
1. Ribbed portion of the spark plug
36 - Maintenance
Continue to tighten propeller nut until nut slots and ANTICORROSION ANODES
cotter pin hole are aligned. Install new cotter pin
and bend ends to secure.
Your motor is equipped with one or more anodes
that protect it from galvanic corrosion. Refer to Fea-
tures for anode location. Disintegration of the an-
ode is normal and indicates it is working. Check
each anode periodically. Replace anodes smaller
than 2/3 their original size. See your Dealer for re-
placements.
1. Thrust washer
2. Spacer
3. Propeller nut
4. Cotter pin
Remove block of wood. Make sure engine is in

NEUTRAL; give propeller a spin. It must turn freely.
Repair
If your propeller hits a solid object, the impact is par-
tially absorbed by the rubber bushing in the hub to
help prevent damage to the engine. A strong impact
can damage the hub and propeller blades. Damage
to blades can cause unusual and excessive vibra-
tion. Damage to the hub can cause excessive en-
gine RPM with little forward movement.
IMPORTANT: Avoid or limit operation using a dam-
aged propeller. Carry a spare propeller.
Keep your propeller in good condition. Use a file to
smooth slight damage to blade edges. See your
Dealer for repair of serious damage.
Galvanic corrosion destroys underwater metal
parts and can occur in fresh or salt water; however,
salt, brackish and polluted waters will accelerate
corrosion.
Metal-based antifouling paint on the boat or motor
and the use of improperly installed shore power in
the area of your moored boat will also accelerate
corrosion.
IMPORTANT: NEVER paint the anode, its fasten-
ers, or its mounting surface. Painting will reduce its
corrosion protection.
Maintenance - 37
TROUBLE CHECK CHART
IMPORTANT: If you are unable to identify or solve the problem, contact your Dealer.
SYMPTOM POSSIBLE CAUSE

Engine will not start • Not following starting instructions. Refer to Engine Starting.
• Fuel tank empty.
• Fuel hose disconnected, kinked.
• Fuel system contaminated with water or dirt.
• Fuel filter obstructed.
• Cold engine – Engine not primed.
• Warm engine – Engine flooded. Disconnect fuel hose at engine,
push in choke or primer, crank engine. If it starts, run until cleared.
If it fails to start, wait a few moments and try again.
• Spark plugs incorrect. Refer to Engine Specifications.
• Spark plugs improperly gapped, carboned, burned or wet.
• Ignition system component failure.
Engine will not idle properly • Motor angle excessive.
• Spark plugs damaged or incorrect. Refer to Engine Specifica-
tions.
• Carburetor mixture out of adjustment.
• Fuel/oil mixture incorrect.
Engine loses power • Spark plugs damaged or incorrect. Refer to Engine Specifica-
tions.
• Fuel filter obstructed.
• Water intakes obstructed and cooling system not operating cor-
rectly. Refer to Engine Overheating.
Engine vibrates excessively • Propeller shaft bent.
• Propeller fouled and restricted, blades bent or broken.
• Engine mount(s) damaged.
• S.L.O.W. protection mode activated. Refer to Engine Overheat-
ing.
• Carburetor mixture out of adjustment.
• Steering friction screw loose (if so equipped).
Engine runs, but makes little or • Propeller hub loose, slipping.
no progress • Propeller blades bent or missing.
• Propeller shaft bent.
• Propeller fouled and restricted.
38 - Maintenance
ENGINE MAINTENANCE AND INSPECTION SCHEDULE
Routine maintenance is necessary for all mechanized products. Periodic maintenance contributes to the
product’s life span. The following maintenance chart provides guidelines for engine maintenance and in-
spection scheduled to be performed by you and/or by an authorized Dealer. The schedule should be ad-
justed according to operating conditions and use.
The recommended lubricants have been formulated to protect bearings, gears and engine components.
They must be used to avoid damage caused by improper lubrication.
IMPORTANT: Schedules for rental operations, commercial applications or high hour use will require
greater frequency of inspection and maintenance.
Engine Maintenance and Inspection Schedule

Frequency
Every 100 Hours
Every 200 Hours

Every 50 Hours
or Biannually
or 6 months
or Annually
Inspection
Each Use
10-Hour
Engine
Care
Description Product
Tilt tube, inspect and lubricate (1) 7 Every 60 days / Every 30 in Saltwater
Upper tilt cylinder rod, lubricate (1) 7 Every 60 days / Every 30 in Saltwater
(1)
Steering handle fittings, lubricate 7 Every 60 days / Every 30 in Saltwater
Clamp screws, lubricate (1) 7 Every 60 days / Every 30 in Saltwater
Swivel bracket / tilt support bracket, inspect 7 Every 60 days / Every 30 in Saltwater
and lubricate (1)
Throttle and shift linkage, inspect and 7 Every 60 days / Every 30 in Saltwater
lubricate (1)
Control shaft bushings, control lever 7 Every 60 days / Every 30 in Saltwater
bearings, carburetor linkage, roller (cam
follower), lubricate (1)
Throttle cable bushings, spark advance 7 Every 60 days / Every 30 in Saltwater
linkage, lubricate (1)
Lubrication and corrosion protection for 4 Every 60 days / Every 30 in Saltwater
metallic components
Anticorrosion anodes, verify operation O D
Water intake screens, verify condition O D
Overboard water pump indicator, verify O D
operation
Steering friction/system check O D
Throttle and shift operation, verify function O D
Emergency stop circuit and lanyard, verify O D
function
Starter, inspect cord O D
Flush cooling system O
Clamp screws, tighten O
Emergency Start Cord, onboard and inspect O
Operator’s Guide, onboard O
Maintenance - 39
Engine Maintenance and Inspection Schedule
Frequency
Every 100 Hours
Every 200 Hours

Every 50 Hours
or Biannually
or 6 months
or Annually
Inspection
Each Use
10-Hour
Engine
Care
Description Product
Engine upper and lower motor covers, clean O
and wax
Operator’s Guide, review O
Fuel system components, inspect and repair D D
leaks (2)
Fuel filter inspection, eliminate contamination D D
Fastener inspection, tighten loosened D D
components
Thermostat, inspect and verify operation (2) D D
Engine to transom mounting hardware, re- D D
torque
Electrical and ignition wires and connections, D D
inspect
Gearcase lubricant replace 5 D D
Powerhead synchronization and linkage, 6 D D
inspect (2)
Gearcase lubricant, inspect fill level and 5 D
condition of lube
Fuel filter(s) replace D
Propeller shaft splines, inspect and lubricate 6 D
Spark plugs, replace (2) D
Decarbonize 8 D
Driveshaft splines, inspect and lubricate 7 D
Water pump, inspect and replace D
(1) Also recommended at 10-Hour Inspection

(2) Emission-related component
D Dealer Performed Service

O Operator Performed Service
4 Evinrude/Johnson anti-corrosion spray or Evinrude/Johnson “6 in 1” multi-purpose lubricant
5 Ultra-HPF gearcase lubricant
6 Triple Guard grease
7 Evinrude/Johnson Molylube P/N 175356
8 Evinrude/Johnson Engine Tuner
40 - Maintenance
INSTALLATION Transom Height and Shaft Length
The transom height dimension listed in Engine
Specifications is the height of the boat transom
WARNING your engine needs. This dimension is measured at
the transom centerline, perpendicular to the bottom
Your engine must not exceed the maximum of the boat.
horsepower indicated on the boat’s capacity
plate. Such overpowering can cause loss of
control. Contact your Dealer or the boat’s
manufacturer if your boat lacks a capacity
plate.
Boats designed for remote-steered engines
might be overpowered by a tiller-steered
engine of the maximum rated horsepower. 1
Ask your Dealer or boat manufacturer if you
are unsure about your boat’s suitability.
Incorrectly matched boat and engine tran-
som heights can cause boat instability and 2 3
loss of control. Refer to Transom Height
and Shaft Length. dr3486
Prevent lateral movement and possible 1. Transom height

engine loss by using the mounting hard- 2. Antiventilation plate
ware supplied or hardware of sufficient size, 3. Final position – 0 to 2 in. (0 to 51 mm)
strength, and quality. Refer to Installing the
Engine. Use this procedure to determine whether or not the
boat’s transom height is correct for the engine’s
A mounting surface that is damaged or too shaft length:
thin to support your engine while underway
If you need a hoist to lift the engine, use as illustrat-
might fail during operation, causing you to
lose control. Be sure the boat’s transom or ed. Refer to Engine Specifications for engine
mounting bracket is structurally sound and weight and choose a hoist accordingly.
between 1 5/8 in. (41 mm) and 2 3/4 in. (70
mm) in thickness.
If equipped, tighten clamp screws by hand, NOT

with tools.
Maintenance - 41
Adjust the motor angle so the antiventilation plate is Installing the Engine
parallel with the boat bottom. Refer to Motor Angle
Adjustment.
The resulting position of the antiventilation plate WARNING
must be no higher than the boat’s bottom and no
lower than 2 in. (51 mm) below it. The outboard must be correctly installed.
Failure to correctly install the outboard
If the resulting position of the antiventilation plate is could result in serious injury, death or prop-
above or below the 0 to 2 in. (0 to 51 mm) range, erty damage. We strongly recommend that
the engine shaft length must be changed or the your Dealer install your outboard to ensure
boat’s transom must be modified. proper installation.
If you install and operate the engine:
Lower than recommended — Serious powerhead IMPORTANT: Follow all directions carefully. The
damage could result from water entry into the lower engine’s warranty will not cover product damage or
engine cover or overloading from an under-revving failure that results from incorrect engine installation.
propeller at wide open throttle.
Higher than recommended — Serious powerhead
damage could result from inadequate cooling or an WARNING
over-revving propeller. Propeller ventilation (slip-
page) often occurs, resulting in poor boat perfor- Even if equipped with clamp screws, your
mance. engine must be bolted to the boat to prevent
it from “working off the transom” during
On a specialty hull, non-planing hull, or on a boat operation.
with a curved transom, these guidelines might not
apply. See your Dealer for special installation infor-
mation. Use all of the mounting hardware supplied with the
motor to ensure proper installation. Instructions are
packed with the mounting kit and are repeated
here.
Mounting hardware
42 - Maintenance
Center the motor on the boat’s transom and over Retighten clamp screws. Install the large washers
the transom plate if one is used. Tighten the clamp and two of the locknuts on the bottom bolts. Install
screws BY HAND ONLY. the small washers and the other two locknuts on the
Drill two 11/32 in. (8,7 mm) holes through the boat’s top bolts. Tighten all nuts securely.
transom on each side of the motor using the stern
bracket holes as guides.
1
3
1. Clamp screws
2. Small washers
1. Drill transom holes 3. Large washers
Apply a good waterproof caulk to bolt shanks. Insert After 30 minutes of operation, retighten clamp
the bolts through the stern bracket and transom. screws by hand. DO NOT use tools to tighten clamp
Loosen clamp screws and apply caulk on and screws. Check clamp screws regularly.
around bolts between stern brackets and transom
to keep water out of the drilled holes.
WARNING
When replacing bolts, screws, or other fas-
teners, use Johnson parts or parts of equiv-
alent strength and material.
Maintenance - 43
AC LIGHTING
3
1. Sleeve
2. Electrical tape covering connection
3. Light bulb
Y – Yellow wire
YG – Yellow/Grey wire
YB – Yellow/Blue wire
Some models have an AC (alternating current)

lighting system for operating lights on a boat. An AC
lighting system is available as an optional kit.
IMPORTANT: Alternating current is generated and
MUST NOT be connected directly to a battery. For
battery charging, install a battery charging kit. See
your Dealer.
Various combinations of light bulbs can be used.
Use 12-volt bulbs of wattage sizes indicated on the
diagram.
Follow the illustration for proper installation of
wires.
Make a 3/8 in. (10 mm) vertical cut through the cen-
ter of the AC light access plug located on the lower
engine cover. Feed wires through plug.
44 - Maintenance
CHANGE OF ADDRESS / CHANGE OF OWNERSHIP
If your address has changed or if there has been a change of ownership, be sure to fill out and mail the
card provided on this page.
Such notification is likewise necessary for your own safety even after expiration of the original warranty,
since BMCA will be in a position to contact you if correction to your outboard becomes necessary.
Outside the U.S. and Canada, this card should be sent to the Bombardier Recreational Products division
where the outboard was registered. Please contact your Dealer or Distributor.
Change of address Change of ownership
Model number
Serial Number
Old address / Previous owner

Last name
First name M.I.
Address
City State
Zip code Country
Phone number
Signature Date
New address / New owner

Last name
First name M.I.
Address
City State
Zip code Country
Phone number
Signature Date
Maintenance - 45
Bombardier Motor Corporation of America
46 - Maintenance
Bombardier Recreational Products
Maintenance - 47
Operator’s Guide
Confirmation of Receipt
Your Dealer
Name:
Address:
Upon delivery of your new Evinrude/Johnson Outboard, complete and sign the form hereunder. Your
Dealer will take receipt of the form for their records.
Receipt
Name:
Address:
Owner of Model No:

Serial No:
(To be completed by customer or selling Dealer)
The Dealer named on this document has instructed me on the operation, maintenance, safety
features and warranty policy, all of which I understand and agree to be bound with. I am also satisfied
with the predelivery set-up and inspection of my Evinrude/Johnson Outboard. I have also received a
copy of the Operator’s Guide.
Signature:
Date:
48 - Maintenance
Readiness Test and a Final Word to the Owner/Operator
The Operator’s Readiness Test....
1. Did you read this Guide from front cover to rear cover?
2. Are you ready to take responsibility for the safe operation of your boat and motor?
3. Do you understand all the safety precautions and instructions contained in this Guide?
4. Do you understand that this Guide contains essential information to help prevent personal injury and
damage to equipment?
5. Are you ready to follow the recommendations in this Guide and take a boating safety course before
you operate your boat and motor?
6. Do you know who to ask if you have any questions about your boat and motor?
7. Do you know your local marine traffic laws?
8. Do you understand that human error can be caused by carelessness, fatigue, overload, preoccupa-
tion, unfamiliarity of operator with the product, drugs and alcohol, just to name a few?
WARNING
It is impossible for this Guide to cover every hazardous situation you may encounter; how-
ever, your understanding of and adherence to essential information contained in this Guide
will build good judgment when boating. Always be alert and careful: a good foundation for
safety.

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Read this Operator Guide thoroughly. It contains important

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2+4® fuel conditioner Johnson®

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© 2004 Bombardier Motor Corporation of America. All rights reserved.

Contact with rotating propeller is likely to result

Avoid standing up or shifting weight suddenly Maintenance

Model Number ___________________________

North America — At the time of purchase, your Declaration of Conformity

1. SCOPE OF THE LIMITED WARRANTY

2. WARRANTY COVERAGE PERIOD

TWENTY-FOUR (24) CONSECUTIVE MONTHS for private, recreational use; or

3. CONDITIONS TO HAVE WARRANTY COVERAGE

4. WHAT TO DO TO OBTAIN WARRANTY COVERAGE

6. EXCLUSIONS – The following are not warranted under any circumstances:

ALL INCIDENTAL, CONSEQUENTIAL, DIRECT, INDIRECT OR OTHER DAMAGES OF ANY KIND

Revision March 2004

Item Description Item Description

(1) Use with Optional Kit

Item Description Item Description

Connect the clip to the emergency stop switch. 1

FUEL Minimum Octane

Inside the U.S. 87 (R+M)/2 AKI

Always wipe off any fuel spillage.

14 - Fuel and Oil

MIXING FUEL AND OIL

Use the following chart and these guidelines to mix

Fuel and Oil - 15

16 - Fuel and Oil

Connect the fuel hose to the fuel connector.

1. Fuel hose connector

1. Fuel tank operable vent

If equipped, attach the clip and lanyard assembly to

Start-up (Cold Engine)

Move the shift lever to NEUTRAL. Refer to Shifting

IMPORTANT: If your outboard does not react nor-

IMPORTANT: To avoid engine damage, after start-

If the starter cord breaks or the starter fails, your en-

1. Starter handle bracket screws

Hook the knot of your emergency start cord into the

While seated, pull hard on emergency starting cord

The economy throttle position can save fuel, de-

Trailer your boat with the motor in a vertical posi-

IMPORTANT: Use the tilt grip to tilt your motor; not

Leave the tilt/run lever in RUN when launching boat

Engage Motor should be perpendicular to the water when

Lower motor until tilt support rests solidly on stern

1. Tilt support lever – up position

Lower motor to normal operating position.

To select the correct propeller for your boating ap-

Your engine has a shock absorption system de-

To avoid difficulty when restarting, never run the

IMPORTANT: Provide water supply to the engine

Propeller — Remove and examine. If damaged,

1. Idle speed adjusting knob WARNING

Carburetor Trim Tab

1. Swivel bracket and tilt support

An optional water pressure gauge is recommended

Wash filter with clean solvent; blow dry.

The filter is located under the inlet cover on the fuel

Inspect spark plugs periodically. Replace if elec-

Install propeller nut and tighten to a torque of 120 in.

1. Ribbed portion of the spark plug